FLATTENED WIRE MESH ELECTRODE FOR USE IN AN ELECTROLYZER CELL

1 . An electrolyzer system comprising:

a first half cell with a first electrode; and

a separator disposed adjacent a side of the first half cell, the separator configured to separate the first half cell from an adjacent second half cell, wherein the first electrode is in contact with a face of the separator, and

wherein the first electrode comprises a mesh, wherein portions of the mesh that are in contact with the separator are flattened.

2 . The system of claim 1 , further comprising the second half cell, wherein the second half cell comprises a second electrode, the second electrode in contact with the separator, and wherein the second electrode comprises a mesh, wherein portions of the mesh of the second electrode that are in contact with the separator are flattened.

3 . The system of claim 2 , wherein the mesh in the first electrode or the mesh of the second electrode, or both meshes comprise an expanded mesh or a mesh formed from woven wires.

4 . The system of claim 2 , wherein the portions of the mesh of one or both of the first electrode and the second electrode are flattened by mechanical modification of the mesh.

5 . The system of claim 4 , wherein the mechanical modification comprises abrasion of the portions of the mesh of the first or second electrodes, or by compressive flattening of the portions of the mesh of the first or the second electrodes.

6 . The system of claim 4 , wherein the mechanical modification comprises calendering of the mesh of the first electrode or the second electrode to compress the portions of the mesh of the first electrode or the second electrode on one or both sides of the respective mesh.

7 . The system of claim 3 , wherein the woven wires of one or both of the first electrode or the second electrode comprise a first set of wires extending in a first direction and a second set of crossing wires extending in a second direction that is angled relative to the first direction, wherein the portions of the mesh that are flattened are located on the first set of wires where each of the first set of wires crosses over one of the second set of crossing wires and on the second set of wires where each of the second set of crossing wires crosses over one of the first set of wires.

8 . The system of claim 2 , wherein the first electrode is a cathode, and the second electrode is an anode.

9 . The system of claim 1 , wherein the separator is an ion exchange membrane.

10 . A method of electrolysis, comprising:

providing an electrolytic cell comprising a first half cell and a second half cell, wherein the first half cell comprises a first electrode and an electrolyte, and wherein the second half cell comprises second electrode and an electrolyte, the first half cell coupled to the second half cell, wherein a separator is disposed between the first half cell and the second half cell, and

wherein one or both of the first electrode and the second electrode comprises a mesh having peaks, and wherein at least some of the peaks are flattened;

passing a current through the electrolysis cell; and

producing hydrogen at one of the first electrode and the second electrode, and producing oxygen at the other of the first electrode and the second electrode.

11 . The method of claim 10 , wherein the separator is an ion exchange membrane.

12 . The method of claim 10 , wherein the first electrode is a cathode, and the second electrode is an anode.

13 . The method of claim 10 , wherein the mesh is a mesh formed from woven wires or an expanded mesh.

14 . A method of manufacturing an electrolyzer, comprising:

providing or receiving a first electrode, wherein the first electrode comprises a mesh;

providing or receiving a separator;

flattening portions of one or more apexes of the mesh that are configured to contact the separator; and

assembling the first electrode and the separator into an electrolyzer half-cell assembly such that the flat portions of the mesh of the first electrode are in contact with a corresponding face of the separator.

15 . The method of claim 14 , further comprising:

providing or receiving a second electrode, wherein the second electrode comprises a mesh;

flattening portions of one or more apexes of the mesh of the second electrode that are configured to contact the separator; and

assembling the second electrode and the separator into an electrolyzer half-cell assembly such that the flat portions of the mesh of the second electrode are in contact with a corresponding face of the separator; and

coupling the half cell with the first electrode together with the half cell with the second electrode.

16 . The method of claim 15 , wherein assembling the half cell with the first electrode or the half cell with the second electrode comprises compressing one or both of the first electrode and the second electrode into a corresponding face of the separator.

17 . The method of claim 15 , wherein flattening the portions of the mesh in the first electrode or the second electrode comprises mechanically modifying the mesh.

18 . The method of claim 17 , wherein mechanically modifying the mesh of the first electrode or the second electrode comprises abrading or compressing the one or more apexes in the first electrode or the second electrode.

19 . The method of claim 17 , wherein mechanically modifying the mesh of the first electrode or the second electrode comprises calendering the mesh of the first electrode or the second electrode to compress the one or more apexes of the first electrode or the second electrode.

20 . The method of claim 15 , wherein the one or more apexes of the first electrode or the second electrode are on both sides of the mesh.

21 . The method of claim 14 , wherein the separator comprises an ion exchange membrane.

22 . The method of claim 15 , wherein the mesh of one or both of the first and second electrodes comprises a woven mesh or an expanded mesh.